Introduction...3. Vehicle Identification and Specifications...8. Things to Know Before You Operate Your Vehicle...16

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1 Table of Contents Introduction...3 Vehicle Identification and Specifications...8 Things to Know Before You Operate Your Vehicle...16 Understanding the Standard Features of Your Vehicle...21 Understanding the Optional Features of Your Vehicle...56 Operation and Maintenance...73 Warranty and Customer Service Word Index GEM Owner s Manual - Page

2 GEM Owner s Manual - Page 2

3 Introduction CONTENTS About this Manual...4 Introduction to Safe Ownership of GEM NEV s...5 Cautions, Warnings and Notes...7 NOTE: This manual is subject to change. For the latest version please visit and click on the GEM Library. WARNING! Any modifications or alterations to this vehicle could seriously affect its road worthiness and safety and may lead to an accident resulting in serious injury or death. WARNING! You can be badly injured working on an electric vehicle. Take your vehicle to your dealer or call GEM customer service at for your service needs. GEM Owner s Manual - Page 3

4 Introduction ABOUT THIS MANUAL Thank you for purchasing your GEM vehicle by Global Electric Motorcars, LLC. Your vehicle is designed to operate exclusively on battery power. It is an emission-free vehicle. The ideal application for a battery-powered neighborhood electric vehicle (NEV) occurs when the daily driving pattern is predictable and the distance is relatively short. The GEM company objective includes customer safety and product satisfaction. This Owner s Manual is designed to acquaint you with the proper and safe operation of your GEM vehicle. Please take the time to read and understand the manual before operating your vehicle. Maintenance schedules and general care instructions are included in the Operation and Maintenance section. This manual is applicable to the following GEM models: The GEM e2 (two passenger), GEM e4 (four passenger), GEM es (two passenger short-back), GEM el (two passenger long-back), el XD (two passenger extra duty long-back), and the e6 (six passenger). GEM Owner s Manual - Page 4

5 Introduction If questions arise after reading the manual, contact GEM Customer Service at Please have your Vehicle Identification Number (VIN) and date of purchase information available. NOTE: All information and specifications in this Owner s Manual are current at the time of printing. However, due to GEM s policy of continuous product improvement, we reserve the right to make changes, at any time, without written notice or obligation. INTRODUCTION TO THE SAFE OWNERSHIP OF GEM NEIGHBORHOOD ELECTRIC VEHICLES GEM battery electric vehicles are different from vehicles you might be accustomed to owning. Special precautions should be followed when owning and operating a GEM vehicle. Please read this Manual and pay particular attention to the cautions and warnings in this Manual, as well as those placed on the vehicle in various locations. In general, GEM battery electric vehicles are designed to meet U.S. Federal Government safety requirements for a special class of vehicle known as Low Speed Vehicles. By this very name, and implicit in these safety requirements, these vehicles are intended only for use at low speed, up to 25 mph, and on public roads (governed by individual state laws) where the speed limits are correspondingly low. GEM Owner s Manual - Page 5

6 Introduction Specific to GEM vehicles, the following safe habits should always be followed: GEM vehicles are open vehicles. For this reason, safety belts should always be worn by all occupants to prevent being thrown from the vehicle during operation. If your GEM is equipped with optional canvas or plastic doors, these were designed and are intended only to keep wind and water out of the vehicle and should not be relied upon to keep occupants in the vehicle or to protect them in case of collision. GEM vehicles are not designed to meet any collision or roll-over requirements. Therefore, you should always drive your GEM vehicle in a safe manner while being alert to potential dangerous situations around you. As with all motor vehicles, never drink alcohol and attempt to drive a GEM vehicle. Operate a GEM vehicle only on public or private roads where the speed limits are appropriate for low speed vehicles (individual state laws vary, so check with your DMV) and the traffic is light. You should never operate a GEM vehicle so that you are an obstacle and become an annoyance for faster moving traffic. GEM vehicles are designed to be recharged from a standard 120 VAC-15 amp electrical outlet that is ground-fault protected. Charging from a circuit of lesser capacity and/or using a cord from the outlet to the GEM vehicle that is not sufficient in wire gauge could create a fire hazard. Please consult this Manual for the proper extension cord gauge which depends on its length. GEM Owner s Manual - Page 6

7 Introduction The voltage in a GEM vehicle battery pack (the battery pack is what you charge and provides the fuel to the GEM s electric drive system) is sufficient to cause death by electrocution. For this reason, GEM owners should NEVER attempt to do any maintenance or repair work on their GEM vehicle s electric drive system, including the battery pack, unless they have had special training. The one exception is inspection and refilling, if necessary, of the water in flooded type batteries that can be ordered with GEM vehicles. In this Owner s Manual, the above safe ownership and operation habits will be pointed out to you as the different aspects of owning and operating a GEM vehicle are explained. Please read, understand and abide by them for years of safe operation and enjoyment of your GEM Neighborhood Electric Vehicle. Cautions, Warnings, and Notes Throughout this owners manual you will find the words WARNING! and CAUTION! These serve as reminders that attention is required. WARNING! indicates an immediate hazard, which could result in an accident causing bodily injury. CAUTION! identifies something that could result in damage to your vehicle. You will also find information preceded by the word NOTE. Notes are for your information and to make procedures more easily understood. GEM Owner s Manual - Page 7

8 Vehicle Identification and Specifications CONTENTS Vehicle Information...9 General Specifications...10 GEM Owner s Manual - Page 8

9 Vehicle Identification and Specifications Vehicle Information 1 Figure 1 - VIN/Certification Label Location 0001 For all model vehicles, the vehicle identification number (VIN) can be found on the VIN/Certification Label, located on the left rear section of the roof panel. The VIN indicates the model year, the model type and the serial number of the vehicle. Note: Be sure to record the Vehicle Identification Number in the space provided. Vehicle Identification Number (VIN): Key # (Stamped on Key) Optional Rear Accessory # (Stamped on Key) Date purchased: / / GEM Owner s Manual - Page 9

10 Vehicle Identification and Specifications General Specifications GEM e2 Specifications Motor: Drive System: Tire: Battery Pack: Accessory Power Supply: Onboard Charger: Vehicle Width: 55 Vehicle Length: 99 Vehicle Height: 70 Wheelbase: 72 Turning Circle: Curb Weight: GVWR: GE Heavy Duty 5 hp, shunt DC electric motor Single speed front wheel drive transaxle 2-ply street rated tires Sceptor TR13 P185/70R13 86T GoodYear 10 turf tire available Six 12-volt lead acid gel batteries of specific make and model number 12 volt, 30 amp DC/DC converter 120 volt 15 amp 60 Hz AC input volt DC output 24 feet* 1120 lbs lbs. Payload Capacity: 730 lbs.** (options + passengers + cargo) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 10

11 Vehicle Identification and Specifications General Specifications GEM e4 Specifications Motor: Drive System: Tire: Battery Pack: Accessory Power Supply: Onboard Charger: Vehicle Width: 55 Vehicle Length: 128 Vehicle Height: 70 Wheelbase: 102 Turning Circle: Curb Weight: GVWR: GE Heavy Duty 5 hp, shunt DC electric motor Single speed front wheel drive transaxle 2-ply street rated tires Sceptor TR13 P185 Six 12-volt lead acid gel batteries of specific make and model number 12 volt, 30 amp DC/DC converter 120 volt 15 amp 60 Hz AC input volt DC output 32 feet* 1280 lbs lbs. Payload Capacity: 920 lbs.** (options + passengers + cargo) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 11

12 Vehicle Identification and Specifications General Specifications GEM es Specifications Motor: Drive System: Tire: Battery Pack: Accessory Power Supply: Onboard Charger: Vehicle Width: 55 Vehicle Length: 108 Vehicle Height: 70 Wheelbase: 72 Turning Circle: Curb Weight: GVWR: GE Heavy Duty 5 hp, shunt DC electric motor Single speed front wheel drive transaxle 2-ply street rated tires Sceptor TR13 P185/70R13 86T Six 12-volt lead acid gel batteries of specific make and model number 12 volt, 30 amp DC/DC converter 120 volt 15 amp 60 Hz AC input volt DC output 25 feet* 1160 lbs lbs. Payload Capacity: 690 lbs.** (options + passengers + cargo) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 12

13 Vehicle Identification and Specifications General Specifications GEM el Specifications Motor: GE Heavy Duty 5 hp, shunt DC electric motor Drive System: Single speed front wheel drive transaxle Tire: 2-ply street rated tires Nanking /70R-12 2-ply street rated tires Sceptor TR 13 P185/70R13 86T (w/heavy duty option) Battery Pack: Six 12-volt lead acid gel batteries of specific make and model number Nine 8 volt lead acid gel batteries of specific make and model number (w/ heavy duty option) Accessory Power Supply: 12 volt, 30 amp DC/DC converter Onboard Charger: 120 volt 15 amp 60 Hz AC input volt DC output Vehicle Width: 55 Vehicle Length: 144 Vehicle Height: 70 Wheelbase: 114 Turning Circle: 35 feet* Curb Weight: 1230 lbs. GVWR: 2300 lbs. Payload Capacity: 770 lbs.** (options + passengers + cargo) TBD lbs.** (w/heavy duty option) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 13

14 Vehicle Identification and Specifications General Specifications GEM el XD Specifications Motor: Drive System: Tire: Battery Pack: Accessory Power Supply: Onboard Charger: Vehicle Width: 55 Vehicle Length: 144 Vehicle Height: 70 Wheelbase: 114 Turning Circle: Curb Weight: GVWR: GE Heavy Duty 5 hp, shunt DC electric motor Single speed front wheel drive transaxle 2-ply street rated tires Sceptor TR13 P185/70R13 86T Nine 8-volt lead acid gel batteries of specific make and model number 12 volt, 30 amp DC/DC converter 120 volt 15 amp 60 Hz AC input volt DC output 35 feet* 1570 lbs lbs. Payload Capacity: 1430 lbs.** (options + passengers + cargo) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 14

15 Vehicle Identification and Specifications General Specifications GEM e6 Specifications Motor: GE Heavy Duty 5 hp, shunt DC electric motor Drive System: Single speed front wheel drive transaxle Tire: 2-ply street rated tires Sceptor TR13 P185/70R13 86T Battery Pack: Six 12-volt lead acid gel batteries of specific make and model number (e6 w/s option) Nine 8-volt lead acid gel batteries of specific make and model number Accessory Power Supply: 12 volt, 30 amp DC/DC converter Onboard Charger: 120 volt 15 amp 60 Hz AC input volt DC output Vehicle Width: 55 Vehicle Length: 162 Vehicle Height: 70 Wheelbase: 133 Turning Circle: 39 feet* Curb Weight: 1560 lbs lbs w/s option GVWR: 3000 lbs. Payload Capacity: 1440 lbs.** (options + passengers + cargo) *The turning circle is the diameter of a circle required to make a U-turn maneuver **These weight limits are approximate. The GVWR must never be exceeded. GVWR is the actual weight of the vehicle plus the weight of the entire payload of passengers and cargo. GEM Owner s Manual - Page 15

16 Things to Know Before You Operate Your Vehicle CONTENTS Driving and Alcohol...17 Safety Information...18 GEM Owner s Manual - Page 16

17 Things to Know Before You Operate Your Vehicle Driving and Alcohol Your ability to drive your GEM vehicle can be seriously impaired with blood alcohol levels far below the legal minimum. If you are drinking alcohol, don t drive. Ride with a designated non-drinking driver, call a cab, or use public transportation. WARNING! Driving after drinking alcohol can lead to an accident. Your perceptions are less sharp, your reflexes are slower, and your judgment is impaired when you have been drinking. Never drink alcohol and drive. WARNING! Drinking alcohol can seriously impair your ability to operate this vehicle. GEM Owner s Manual - Page 17

18 Things to Know Before You Operate Your Vehicle SAFETY INFORMATION Your vehicle is battery powered. If handled improperly, batteries can be dangerous. Follow the precautions provided on pages during charging operations to avoid personal injury or damage to electrical components in the vehicle. Read the Owner s Manual before operating this vehicle. Charge vehicle in a well-ventilated area only. Keep children away from the vehicle during charging. Batteries can emit explosive hydrogen gases when charging. Keep sparks and flames away from the battery area of the vehicle. Tools, wires and metal objects can cause sparks when shorted across the battery connections. Follow all instructions carefully when dealing with batteries. The batteries in the GEM vehicle are either 12 volt or 8 volt lead acid batteries. They are connected in a pack configuration to produce HIGH VOLTAGE DC (72 to 85 volts). These batteries are either Flooded electrolyte type or gel electrolyte type and are selected specifically to optimize the operation and performance of your vehicle. Never use or substitute any battery other than the original factory approved batteries. GEM Owner s Manual - Page 18 WARNING!

19 Things to Know Before You Operate Your Vehicle Electrolyte can leak from damaged or defective flooded batteries. Avoid contact with skin, eyes or clothing. Batteries contain acid, which can cause severe burns. If battery fluid comes in contact with your skin, flush the affected areas with water for at least 15 minutes and then seek medical assistance. Internal ingested: Get medical assistance as soon as possible. Contact with eyes: Flush with water and get medical assistance as soon as possible. While you are being driven to get medical assistance, continue to rinse your eyes by using a sponge or soft cloth saturated with water. CAUTION! When checking the electrolyte level in flooded batteries, be careful to never touch the battery terminals. WARNING! Battery posts, terminals, and related accessories contain lead and lead compounds. Always wash hands after handling the battery. WARNING! Improper handling of high voltage wiring, batteries, or control systems could result in serious or fatal injury by electric shock. Only qualified technicians should repair or access high voltage wiring, battery packs, and associated systems. GEM Owner s Manual - Page 19

20 Things to Know Before You Operate Your Vehicle roll over warning Because of the higher center of gravity and the narrower track of this vehicle, it may roll over when some other vehicles may not. Do not attempt sharp turns or abrupt maneuvers or other unsafe driving actions that can cause loss of vehicle control and possible roll over. Failure to operate this vehicle safely may result in an accident, roll over, andserious injury or death. Because of its open-body construction, your vehicle offers less protection than closed vehicles in the event of an accident. CAUTION! The top is not designed to carry any additional loads such as roof racks, spare tires, building, hunting, or camping supplies, and/or luggage, etc. Also, it was not designed as a structural member of the vehicle, and thus cannot properly carry any additional loads other than environmental (rain, snow, etc.) GEM Owner s Manual - Page 20

21 Understanding the Standard Features of Your Vehicle CONTENTS Instrument Pod...22 Windshield Wipers...23 Foot Pedals...36 Parking Brake...37 Main Disconnect Switch...39 Safety Belts...42 Convenience Items...41 GEM Owner s Manual - Page 21

22 Understanding the Standard Features of Your Vehicle Instrument Pod Turn Signal/Windshield Wiper/Horn Lever 2. Trip/Odometer Switch 3. Headlight Switch 4. Forward/Reverse Switch 5. Key Switch 6. LCD Display GEM Owner s Manual - Page 22 Figure 2 - Instrument Pod Note: Further explanation of these vehicle features are found on the next nine pages. 2

23 Understanding the Standard Features of Your Vehicle Turn Signal/Windshield Wiper/Horn Lever Figure 3 - Turn Signal Lever The turn signal lever is multi-functional, controlling the turn signals, horn and wiper. Figure 3 illustrates how to activate the different functions. Turn Signal For a left turn, move the lever down until it clicks. For a right turn, move the lever up until it clicks. CAUTION! The turn signal lever is not self-canceling. After completing the turn, return the lever to the center (off) position. An audible tone alert will sound after the turn signal has been on for 45 seconds. GEM Owner s Manual - Page 23

24 Understanding the Standard Features of Your Vehicle Horn Press the turn signal lever inward toward the instrument pod to activate the horn. Windshield Wiper Pull the turn signal lever towards the steering wheel to turn on the windshield wiper. Push the turn signal lever away from the steering wheel to turn off. TRIP METER/Odometer Switch The trip switch has three functions: (1) toggling between the odometer and the trip meter; (2) reset the trip meter; (3) change the function of the speedometer and odometer from miles-per-hour (MPH) to kilometers-per-hour (km/h) and miles to kilometers. Using the Trip/Odometer Switch 1. Pressing the trip switch for less than 2 seconds will toggle between the odometer and trip meter modes on the display. 2. Pressing the trip switch for 3-9 seconds, while the display is in the trip mode, will reset the trip meter to zero. (TRIP must be lit on the displaysee page 27). 3. Pressing the trip switch for seconds, while the display is in theodometer mode will change the display functions from MPH to km/h andmiles to km. GEM Owner s Manual - Page 24

25 Understanding the Standard Features of Your Vehicle Headlight Switch Headlight switch turns the headlights and taillights on and off. Forward/reverse Switch Drive High With the key turned on and High selected, pushing down on the accelerator pedal will move the vehicle in a forward direction with the speed range of 0-25 MPH. This mode refers to APPROVED TRAFFIC routes based on Low Speed Vehicle (LSV) regulations for your area. Drive Low With the key turned on and Low selected, pushing down on the accelerator pedal will move the vehicle in a forward direction with the speed range of 0-15 mph. When Low is selected, the acceleration and speed of the GEM is limited. Reverse With the key switch on and Reverse selected, pushing down on the accelerator pedal will move the vehicle in reverse. The top speed in the reverse direction is limited for safety. Note: Your GEM is equipped with a reverse warning device that sounds when the key is on and the vehicle direction switch is in the reverse position. GEM Owner s Manual - Page 25

26 Understanding the Standard Features of Your Vehicle Always bring the vehicle to a complete stop before changing the position of the forward/reverse switch. Key Switch When the key is in the ON position (turned clockwise), the display will light up and all accessories may be turned on. When the key is in the OFF position, the car will not accelerate but accessories and lights will remain on for approximately 20 seconds. Zero Speed Detect If the vehicle is moving while the key switch is on and accelerator pedal up (not depressed), the electric motor will resist vehicle motion. GEM Owner s Manual - Page 26 CAUTION! WARNING! Never turn the key to the OFF position while the vehicle is in motion. This could lead to loss of speed control and loss of control of the vehicle. This can cause a serious accident. CAUTION! Do not leave the key in the ON position when not in use. Doing so will discharge the batteries.

27 Understanding the Standard Features of Your Vehicle LCD Display P A O B C D E F G H N M L I J K Figure 4 - LCD Display GEM Owner s Manual - Page 27

28 Understanding the Standard Features of Your Vehicle LCD Display Indicators A Left Turn Indicator B Low Fluid Level/Parking Brake On Indicator C High Motor Temperature Warning Indicator D Odometer/Trip Meter E Charger Connected Indicator F State of Charge Indicator G Current Limiting Mode Indicator H Safety Belt Warning Indicator I Reverse Indicator J Drive-Low Setting K Drive-High Setting L NOT ACTIVE IN VEHICLE M Headlight Indicator N Service Required Indicator O Right Turn Indicator P Speedometer/Error Code Display *Vehicle will not move when the parking brake is engaged and parking brake lamp is lit. Note: These indicators are defined on the next several pages. GEM Owner s Manual - Page 28

29 Understanding the Standard Features of Your Vehicle Turn INDICATORS The turn signal arrows will flash corresponding to the direction of the turn signal lever. High Temperature Motor OR MOTOR CONTROLler If the motor temperature icon is lit or an error code 41 is displayed in the speedometer/ error code display, your motor or motor controller may be overheating. Climbing steep grades while hauling heavy loads may overheat the motor or controller and shorten component life. brake failure warning If the brake warning icon is lit, there may be a problem with your braking system. It could be an indication of the following: Low brake fluid Air in the brake system WARNING! Worn brake hoses can burst and cause brake failure. You could have an accident. If you see any signs of cracking, scuffing, or worn spots, have the brake hoses replaced immediately. WARNING! Riding the brakes can lead to brake failure and possibly an accident. Driving with your foot resting or riding on the brake pedal can result in abnormally high brake temperatures, excessive lining wear, possible brake damage, and reduced driving range. You wouldn t have your full braking capacity in an emergency. GEM Owner s Manual - Page 29

30 Understanding the Standard Features of Your Vehicle CAUTION! If the high motor temperature warning indicator is lit, or code 41 is displayed, pull over and park the vehicle in a cool location as soon as possible. Wait until motor temperature is reduced and the high motor temperature icon turns off before continuing to drive. If this condition persists, contact your service provider. Trip meter/odometer The odometer indicates the total distance the vehicle has been driven. This is useful in keeping a record for maintenance. The odometer can be displayed in kilometers or miles. To change from miles to kilometers or to change from odometer to trip meter, see the Odometer Switch/Trip Meter section on page 24. The trip meter is useful for keeping track of specific distances traveled. Speedometer/Error Code The speedometer indicates driving speed in either miles-per-hour (MPH) or kilometers-per hour (km/h). To switch between MPH and km/h, see the Trip Meter/Odometer Switch section on page 24. If the Service icon is lit, an error code will be displayed at the speedometer location. See page 74 for information regarding error codes. GEM Owner s Manual - Page 30

31 Understanding the Standard Features of Your Vehicle Charger Connected The charger connected icon and state of charge gauge turns on approximately 8-10 seconds after the extension cord is plugged in. After charging is 100% complete, the charger connected icon will be the only thing lit and the bar graph will not be illuminated. A green light on the charger itself will also illuminate when the car is 100% charged. To know if the charging process is complete, all ten bars on the state of charge indicator should be illuminated when the car is turn on. If the charger cord is plugged in and neither the charger connected icon nor the state of charge indicators are not illuminated, the charger may not be charging. If this occurs, make sure the main disconnect switch is in the ON position. More information on the charger and charging of the batteries is discussed on pages State of Charge The state of charge indicator shows how much capacity remains in the battery pack. There are 10 bars: 1 red, 1 yellow, and 8 green. After a full charge all the bars should be illuminated when the car is turned on. The far right green bar will be the first to turn off once the battery pack voltage begins to drop. The percent of charge corresponding to each bar is shown below. Bar Color % Of Full Charge 1 Red (Far Left) Less Than 10 2 Yellow Green Green Green Green Green Green Green Green (Far Right) GEM Owner s Manual - Page 31

32 Understanding the Standard Features of Your Vehicle Current Limiting Mode The current limiting mode is designed to protect the batteries and motor. If the current limiting mode icon is illuminated, it is an indication of one of the following issues: Battery Pack Over-Voltage Battery pack over-voltage typically occurs when the vehicle is descending down hills after being fully charged. During descent, the regenerative mode is activated, which returns current to the battery by using the motor as a generator. In some extreme cases, the battery pack might get overcharged. Battery Pack Under-Voltage Battery pack under-voltage would coincide with a low charge reading on the state of charge gauge. If you continue to drive, the acceleration and power will begin to decrease. The controller will eventually shut the vehicle down before allowing battery damage to occur. If the state of charge is low and the current limiting icon is illuminated, pull the vehicle over to a safe location and charge the vehicle. GEM Owner s Manual - Page 32

33 Understanding the Standard Features of Your Vehicle Safety Belt The safety belt icon reminds you to fasten your safety belt. The icon remains on for 45 seconds. WARNING! It is extremely dangerous to ride in a cargo area outside of a vehicle. In a collision people riding in these areas are more likely to be seriously injured or killed. Do not allow people to ride in any area of your vehicle that is not equipped with seats and seat belts. Be sure everyone in your vehicle is in a seat and using a seat belt properly. Drive High/Low/Reverse The drive High/Low/Reverse corresponds to the position of the Forward/Reverse switch. More information regarding this switch can be found on pages 22 and 25 Service If the Service icon is illuminated, an error code will be displayed at the speedometer location. See page 74 for a description and explanation of common error codes. GEM Owner s Manual - Page 33

34 Understanding the Standard Features of Your Vehicle Windshield Wiper Note: The windshield wiper circuit is protected by a 5 amp fuse located in the fuse block behind the fuse access panel. If the wiper is not working check the fuse and if blown, replace it with the same type and rating Wiper Blade and Arm GEM Owner s Manual - Page 34 Figure 5- Windshield Wiper CAUTION! A damaged or worn wiper blade may reduce vision and impair you from seeing well enough to drive safely. A worn wiper blade could damage windshield glass. If your blade becomes damaged or worn, replace it.

35 Understanding the Standard Features of Your Vehicle CAUTION! When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. GEM Owner s Manual - Page 35

36 Understanding the Standard Features of Your Vehicle Foot PEDALS Brake Pedal 2. Accelerator Pedal Figure 6 - Foot Pedals Brake Pedal The brake pedal (Figure 6) is located on the floor to the left of the accelerator pedal. To slow or stop the vehicle, firmly press the brake pedal. Accelerator Pedal The accelerator pedal (Figure 6), is located on the floor, close to the center of the vehicle and is used to control your speed. Pressing down on the pedal will increase speed. WARNING! Always accelerate slowly to prevent possible injury to yourself or others. GEM Owner s Manual - Page 36

37 Understanding the Standard Features of Your Vehicle Parking Brake 1 Figure 7 - Parking Brake (models e2, es, el, el XD) 2 Figure 8 - Parking Brake (models e4, e6) GEM Owner s Manual - Page 37

38 Understanding the Standard Features of Your Vehicle 1. Parking Brake (models e2, es, el, el XD) Figure 7 2. Parking Brake (models e4, e6) Figure 8 The parking brake is located to the lower right of the driver seat. To engage the parking brake, lift up on the handle. To release, press the button on the end of the brake handle and lower it. Note: The parking brake is adjustable and should be checked periodically by a trained service technician. Review the vehicle maintenance schedule on page 104. WARNING! Always fully apply the parking break when leaving your vehicle, or it will roll and may cause damage or injury. Leaving children in a vehicle unattended is dangerous for a number of reasons. A child or other could be injured. Children should be warned not to touch the parking break or the gear selector lever. Don t leave the keys in the ignition. A child could operate controls, or move the vehicle. Be sure the parking brake is fully disengaged before driving. Failure to do so can lead to brake problems due to excessive heating of the rear brakes. GEM Owner s Manual - Page 38

39 Understanding the Standard Features of Your Vehicle MAIN Disconnect Switch AND FUSE PANEL Figure 9 - Main Disconnect Switch The main disconnect switch (MDS) (Figure 9), is located inside the fuse access panel on the lower dash. The switch is clearly labeled ON and OFF. The switch is intended to provide an easy way to disconnect all power to the vehicle during long-term storage. After disconnect is turned off, some power may remain in the system until all capacitors have discharged. Note: The main disconnect switch must be turned ON for operation and charging. The GEM is equipped with a battery charger that will monitor the state of charge of the batteries and will initiate a charge cycle whenever the batteries fall below a predetermined level. If the car will be left unused for an extended period of time, leave the MDS on and the car plugged in. The car will maintain a charge on its own for up to 24 weeks. GEM Owner s Manual - Page 39

40 Understanding the Standard Features of Your Vehicle CAUTION! When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be corrected. CAUTION! Do not turn off disconnect switch while the vehicle is in motion or undergoing recharge unless in the case of an emergency where the vehicle operation or charging requires interruption. WARNING! The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals. HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY TERMINALS GEM Owner s Manual - Page 40

41 Understanding the Standard Features of Your Vehicle CONVENIENCE ITEMS Seat Adjustment - 4 & 6 Passenger Only The front seats on the e4 and e6 models are equipped with manual seat adjustments. The seat adjustment handle is directly under the front of the seat. Move the handle toward the driver s side door, to the left, and move the seat to the desired position. Using body pressure, move forward and rearward on the seat to assure the seat adjusters are latched securely. 1 Figure 12 - Seat Adjustment Handle 1. Seat Adjustment Handle GEM Owner s Manual - Page 41

42 Understanding the Standard Features of Your Vehicle Safety Belts Figure 10 - Safety Belts (Bench Seat) Figure 11 - Safety Belts (Bucket Seat) 1. Belt 2. Latch 3. Buckle The GEM is equipped with safety belts for both driver and passengers. GEM Owner s Manual - Page 42

43 Understanding the Standard Features of Your Vehicle Research has shown that safety belts save lives. Safety belts can reduce the seriousness of injuries in a single vehicle accident. Some of the worst injuries happen when people are thrown from the vehicle. Safety belts provide protection, and they reduce the risk of injury caused by striking the inside of the vehicle. Everyone needs to buckle up all the time, even for short trips. WARNING! Wearing a safety belt incorrectly is dangerous. Safety belts are designed to go around the large bones of your body. These are the strongest parts of your body and can take the forces of a collision best. Wearing your safety belt incorrectly could increase your risk for injury in a collision. You could suffer internal injuries, or even slide out of part of the belt. Use the instructions in this manual to insure you and your passengers are wearing the safety belts properly. Two people should never be belted into a single safety belt. People belted together can crash into one another in an accident, causing injury. Never use a lap/shoulder belt for more than one person, no matter the size of the person. GEM Owner s Manual - Page 43

44 Understanding the Standard Features of Your Vehicle WARNING! In a collision, you and you passengers can suffer injuries, including fatalities, if you are not properly buckled up. You can strike the interior of your vehicle or other passengers, or you can be thrown out of the vehicle. Always be sure you and others in your vehicle are buckled up properly. Proper Use Of Your Lap and Shoulder Belt 1. Enter the vehicle and sit back. 2. The safety belt buckle is located above the back of the seat. Grasp the buckle and pull out the belt. Slide the buckle up the webbing as far as necessary to make the belt go around your lap. 3. When the safety belt is long enough to fit, insert the buckle into the latch until you hear a click. CAUTION! Make sure the button on the latch faces upward or outward, so that you are able to unbuckle your safety belt quickly. 4. Position the lap belt across your thighs, and below your abdomen. To remove slack in the lap belt portion of the belt, pull up on the shoulder belt. To loosen the lap belt if it is too tight, tilt the buckle and pull on the lap belt. A snug belt reduces the risk of sliding under GEM Owner s Manual - Page 44

45 Understanding the Standard Features of Your Vehicle the belt in a collision. 5. Position the shoulder belt on your chest so that it is comfortable and not resting on your neck. The retractor will withdraw any slack in the belt. 6. To release the belt, push the red button on the latch. If necessary, slide the buckle down the webbing to allow it to retract fully. WARNING! A frayed or torn belt could rip apart in a collision and leave you with no protection. Inspect the belt system periodically, checking for cuts, frays, or loose parts. Damaged parts must be replaced immediately. Do not modify or disassemble the system. Seat belt assemblies must be replaced after a collision if they have been damaged (bent retractor, torn webbing, etc.). GEM Owner s Manual - Page 45

46 Understanding the Standard Features of Your Vehicle CAUTION! Maximum occupancy is limited to six people (including the driver) in the GEM e6, four people in the GEM e4 and two people in the GEM e2, es, el, and el XD. WARNING! A belt that is buckled into the wrong latch will not function or protect you properly. The lap portion of the safety belt could ride too high on your body, possibly causing internal injuries. Always buckle your safety belt into the latch nearest you. A safety belt that is too loose will not function properly. In a sudden stop, you could jerk too far forward, increasing the possibility of injury. Wear your safety belt snugly. A belt that is positioned under your arm is very dangerous. Your body could strike the inside surfaces of the vehicle in a collision, increasing the possibility of injury. A belt worn under the arm can cause internal injuries. Wear the belt over your shoulder. A shoulder belt placed behind you will not protect you from injury during a collision. The lap and shoulder belts are to be used together. GEM Owner s Manual - Page 46

47 Understanding the Standard Features of Your Vehicle SEAT BELTS AND PREGNANT WOMEN We recommend that pregnant women use seat belts throughout their pregnancy. Keeping the mother safe is the best way to keep the baby safe. Pregnant women should wear the lap part of the belt across the thighs and as snug across the hips as possible. Keep the belt low so that it does not come across the abdomen. That way the strong bones of the hips will take the force if there is a collision. SEAT BELT EXTENDER If a seat belt is too short, even when fully extended and when the adjustable upper shoulder belt anchorage (if equipped) is in its lowest position, your dealer can provide you with a seat belt extender. This extender should be used only if the existing belt is not long enough. When it is not required, remove the extender and store it. WARNING! Using a seat belt extender when not needed can increase the risk of injury in a collision. Only use when the seat belt is not long enough when it is worn low and snug, and in the recommended seating positions. Remove and stow the seat belt extender when not needed. GEM Owner s Manual - Page 47

48 Understanding the Standard Features of Your Vehicle Child Restraint Everyone in your vehicle needs to be buckled up at all times - babies and children, too. Every state in the United States and all Canadian provinces require that small children ride in proper restraint systems. This is the law, and you can be prosecuted for ignoring it. Children 12 years and under should ride properly buckled up in a rear seat, if available. According to crash statistics, children are safer when properly restrained in the rear seats, rather than in the front. There are different size and types of restraints for children from newborn size to the child almost large enough for an adult saftey belt. Always check the child seat owner s manual to ensure you have the correct seat for your child. Use the restraint that is correct for your child. In a collision, an unrestrained child, even a tiny baby, can become a missle inside the vehicle. The force required to hold an infant could become so great that you could not hold the child, no matter how strong you are. The child and others could be badly injured. Any child riding in your vehicle should be in a proper restraint for the child s size. GEM Owner s Manual - Page 48 WARNING!

49 Understanding the Standard Features of Your Vehicle infants and Child Restraints Safety experts recommend that children ride rearward-facing in the vehicle until they are at least one year old and weigh at least 20 lbs (9 kg). Two types of child restraints can be used rearward-facing: infant carriers and convertible child seats. The infant carrier is only used rearward-facing in the vehicle. It is recommended for children who weigh up to about 20 lbs (9 kg). Convertible child seats often have a higher weight limit in the rearward-facing direction than infant carriers do, so they can be used rearward-facing by children who weigh more than 20 lbs (9 kg) but are less than one year old. Both types of child restraints are held in the vehicle by the lap/shoulder belt. This vehicle is not equipped with a latch child restraint anchorage system. The lap/shoulder belt must be used to secure both types of child restraints into the vehicle. WARNING! Improper installation can lead to failure of an infant or child restraint. It could become loose in a collision. The child could be badly injured or killed. Follow the manufacturer s directions exactly when installing an infant or child restraint. GEM Owner s Manual - Page 49

50 Understanding the Standard Features of Your Vehicle tips for getting the most out of your child restraint Before buying any restraint system, make sure that it has a label certifying that it meets all applicable Safety Standards. The manufacturer also recommends that you try a child restraint in the vehicle seats where you will use it before you buy it. The restraint must be appropriate for your child s weight and height. Check the label on the restraint for weight and height limits. Carefully follow the instructions that come with the restraint. If you install the restraint improperly, it may not work when you need it. All passenger seat belts are equipped with cinching latch plates. Seat belts are designed to keep the lap portion tight around the child restraint so that it is not necessary to use a locking clip. If the seat belt has a cinching latch plate, pulling up on the shoulder portion of the lap/shoulder belt will tighten the belt (the cinching latch plate will keep the belt tight, however, any seat belt system will loosen with time, so check the belt occasionally and pull it tight if necessary). In the rear seat, you may have trouble tightening the lap/shoulder belt on the child restraint because the buckle or latch plate is too close to the belt path opening on the restraint. Disconnect the latch plate from the buckle and twist the short buckle-end belt GEM Owner s Manual - Page 50

51 Understanding the Standard Features of Your Vehicle several times to shorten it. Insert the latch plate into the buckle with the release button facing out. If the belt still cannot be tightened, or if pulling and pushing on the restraint loosens the belt, disconnect the latch plate from the buckle, turn the buckle around, and insert the latch plate into the buckle again. If you still cannot make the child restraint secure, try a different seating position. Buckle the child into the restraint exactly as the manufacturer s instructions tell you. When your child restraint is not in use, secure it in the vehicle with the seat belt or remove it from the vehicle. Do not leave it loose in the vehicle. In a sudden stop or collision, it could strike the occupants or seat backs and cause serious personal injury. NOTE: For additional information refer to or call SEATCHECK. Other children and child restraints Children who weigh more than 20 lbs (9 kg) and who are older than one year can ride forward-facing in the vehicle. Forward-facing child seats and convertible child seats used in the forward-facing direction, are for children who weigh 20 to 40 lbs (9 to 18 kg), and who are older GEM Owner s Manual - Page 51

52 Understanding the Standard Features of Your Vehicle than one year. These child seats are also held in the vehicle by the lap/shoulder belt. The belt-positioning booster seat is for children weighing more than 40 lbs (18 kg), but who are still too small to fit the vehicle s seat belts properly. If the child cannot sit with knees bent over the vehicle s seat cushion while the child s back is against the seat back, they should use a belt-positioning booster seat. The child and belt-positioning booster seat are held in the vehicle by the lap/shoulder belt. children too large for booster seats Children who are large enough to wear the shoulder belt comfortably, and whose legs are long enough to bend over the front of the seat when their back is against the seat back, should use the lap/shoulder belt in a rear seat. Make sure that the child is upright in the seat. The lap portion should be low on the hips and as snug as possible. Check belt fit periodically. A child s squirming or slouching can move the belt out of position. If the shoulder belt contacts the face or neck, move the child closer GEM Owner s Manual - Page 52

53 Understanding the Standard Features of Your Vehicle to the center of the vehicle. Never allow a child to put the shoulder belt under an arm or behind their back. Not all child restraint systems will be installed as we have described here. Again, carefully follow the instructions that come with the child restraint system. transporting pets Pets should be restrained in the rear seat in a pet harness, or in a pet carrier that is secured by seat belts. GEM Owner s Manual - Page 53

54 Understanding the Standard Features of Your Vehicle Cup Holder 2. Glove Box Door 3. Package Tray 4. Glove Box Lock Figure 13 - Upper Dash The glove box (Figure 13), is located on the top center of the upper dash and is equipped with a lock to protect against theft or damage. The upper dash also contains a package tray and four cup holder locations. Your ignition key will lock and unlock the glove box. Turn 1/4 turn counter clockwise to unlock. GEM Owner s Manual - Page 54

55 Understanding the Standard Features of Your Vehicle Electrical wiring, circuit boards and components are located under and behind the upper and lower dash. CAUTION! Liquids can damage electrical components and the circuit board. Handle liquids with care. Do not spray water directly into the upper or lower dash. GEM Owner s Manual - Page 55

56 Understanding the Optional Features of Your Vehicle REAR Accessory OPTIONS Figure 15 - TrunkBack TM Figure 16 - LinksBack TM Figure 17 - Clip-In StakeBack GEM Owner s Manual - Page 56

57 Understanding the Optional Features of Your Vehicle 1. Release Handle - Your ignition key opens this lock, always lock after changing optional accessory backs. 2. Cover 3. Cover Lock - There is a separate key for this lock. Rear accessories options are available from your dealer and they are interchangeable. CAUTION! Use only GEM approved rear accessories. Others may cause damage to the locking system or vehicle, and will void warranty. WARNING! DO NOT OVERLOAD When releasing the back latch, make sure the safety strap is secure prior to turning the release handle. The rear TurnBack/LinksBack accessory can fall suddenly and cause injury or damage to the vehicle if the safety strap is not used. GEM Owner s Manual - Page 57

58 Understanding the Optional Features of Your Vehicle The release handle is located at the rear of the vehicle between the taillights. To remove or install rear accessories: 1. Remove contents of rear accessory. 2. Steady it to prevent it from falling. 3. Unlock the release handle with ignition key. 4. Rotate the release handle clockwise to release. 5. Remove the safety strap. 6. Lift off the GEM. 7. Position the new rear accessory onto the brackets and refasten the safety strap. 8. Push forward to engage lock. Test to make sure it is secure. This is a two stage locking system. If not secure, repeat procedure. 9. Lock the release handle with ignition key. Keep the back latch in a locked position when operating or transporting the vehicle. The rear accessory could fall and cause injury if the safety strap is not used. GEM Owner s Manual - Page 58 CAUTION! WARNING! The capacity of the back is not intended for any type of passenger use. Doing so could result in personal injury.

59 Understanding the Optional Features of Your Vehicle HAZARD WARNING FLASHERS Your vehicle s hazard warning flasher is an emergency warning system. When you activate it, all front and rear directional signals will flash intermittently. Use it when your vehicle is disabled on or near the road. It warns other drivers to steer clear of you and your vehicle. This is an emergency warning system, not to be used when the vehicle is in motion. To activate the warning flashers, press the button on the lower switch bank (below climate controls). To turn the warning flashers off, press the button again. GEM Owner s Manual - Page 59

60 Understanding the Optional Features of Your Vehicle heated seats Heated seats provide comfort and warmth on cold days and can help soothe sore muscles and backs. For 2-passenger vehicles, the front driver and passenger seats are heated. For 4-passenger and 6-passenger vehicles both front and second row seats are heated. The front heated seat switches are located on the seat pedestal directly below the front edge of the seat cushion. The rear heated seat switches are located directly below the rear of the front seat backrests. After keying on the vehicle, you can choose seat heating levels of High, Medium, Low, or Off. Pressing the switch once selects High. Each successive switch press decreases the heat level to Medium, Low, and Off respectively. The heated seat system has an additional safety feature that automatically shuts off the seats 1 hour after turning them on. GEM Owner s Manual - Page heated seat switches.

61 Understanding the Optional Features of Your Vehicle WARNING! Persons who are unable to feel pain to the skin because of advanced age, chronic illness, diabetes, spinal cord injury, medication, alcohol use, exhaustion, or other physical conditions must exercise care when using the seat heater. It may cause burns even at low temperatures, especially if used for long periods of time. Do not place anything on the seat that insulates against heat, such as a blanket or cushion. This may cause the seat heater to overheat. radio The optional AM/FM radio features 12 preset FM stations and 6 preset AM stations. Refer to your Alpine User s Manual for detailed operating instructions. GEM Owner s Manual - Page 61

62 Understanding the Optional Features of Your Vehicle public address system The optional public address (PA) System features a heavy-duty microphone, speaker, and a four-tone siren. Refer to your PA system user s manual for detailed operating instructions. chrome front bumpers The chrome bumpers are for appearance only and will protect the body panels from minor dents and scratches in some parking maneuver situations. They will not provide any protection to the vehicle in front or rear collisions. GEM Owner s Manual - Page 62

63 Understanding the Optional Features of Your Vehicle rugged bumpers The rugged bumpers will protect the body panels for minor dents and scratches in some parking maneuver situations. They will not provide any protection to the vehicle in front or rear collisions. CAUTION! The bumpers are not designed for pushing or towing purposes. Damage to the vehicle may result. GEM Owner s Manual - Page 63

64 Understanding the Optional Features of Your Vehicle grab handle package NOTE: The interior grab handles are not intended to retain passengers in the vehicle. Seat belt must be worn at all times. valet bar Install the Valet Bar as shown below. CAUTION! Do not overload. Hanging loads must never exceed 100 lbs. GEM Owner s Manual - Page 64

65 Understanding the Optional Features of Your Vehicle soft door operation From either inside or outside the vehicle, locate the zipper at the bottom front or mid rear of each door. Unzip the door to open. The door can be held in the open position using the straps and snaps located on the pillars/door supports. GEM Owner s Manual - Page 65

66 Understanding the Optional Features of Your Vehicle framed canvas door operation To open the doors from outside the vehicle, locate the knob and slide in the direction of the arrows (1). To open doors from inside the vehicle, locate the mid-center nylon strap (2) and pull towards the front of the vehicle. To open windows, locate the zipper and unzip to desired position. The window can be stored in the open position by securing with the nylon straps and snaps. 1 2 The doors, hard or soft, do not offer structural protection in the event of an accident and do not change the open body characteristics of the vehicle. The doors only provide protection from the weather. Always use seat belts. Failure to use standard seat belts subjects the driver and passengers to greater risk of being thrown out of an open body vehicle than out of a closed vehicle in an accident which can result in injury or death. GEM Owner s Manual - Page 66 WARNING!

67 Understanding the Optional Features of Your Vehicle steering column lock operation To lock, turn the key forward (clockwise) while turning the steering wheel until you feel the lock/key set into place, then remove the key. To unlock, insert the key and turn it backwards (counterclockwise). enclosed cargo carrier operation To open, insert key and turn lock, pull out and twist T-handle. To close, reverse the process. GEM Owner s Manual - Page 67

68 Understanding the Optional Features of Your Vehicle dome light operation The dome light is turned on or off by pressing the button (1) located on the side of the light. The dome light is powered by 4-AA batteries. To replace the batteries, remove the light cover and install new batteries per the illustration inside the battery compartment. 1 heater/defogger operation The heater/defogger unit can be used to provide vehicle passenger heat, as well as to assist in defogging the windshield. To operate, move the switch (1) located on the dash of the vehicle to the On position. Adjust the airflow to the windshield as needed using the deflectors (2) located on the top of the dash. 2 1 GEM Owner s Manual - Page 68

69 Understanding the Optional Features of Your Vehicle windshield washer operation The windshield washer can be used with the windshield wipers to remove dirt and debris from the vehicles windshield. To operate the washer, first turn on the windshield wipers, then press the washer switch (1) located on the front of the dash. The washer reservoir (2), located in the motor compartment should be checked for fluid levels at regular intervals. Fill the reservoir with windshield antifreeze (not radiator antifreeze) rated for -25 F (-31 C). Operate the system for a few seconds to flush out the residual water. To fill, remove the cap (3) and fill with windshield washer fluid WARNING! Commercial windshield washer solvents are flammable. They could ignite and burn you. Care must be exercised when filling or working around the washer solution. GEM Owner s Manual - Page 69

70 Understanding the Optional Features of Your Vehicle High/low beam headlight operation The high/low beam headlights (1) are operated by moving the headlight switch (2) located on the steering column to the low beam, down position, or the high beam, up position. To turn off the lights, move the switch to the Off center position. 1 2 GEM Owner s Manual - Page 70

71 Understanding the Optional Features of Your Vehicle Accessory outlet 1 1. Accessory Outlet Figure 17 - Accessory Outlet The optional accessory outlet (Figure 17) is located on the lower dash, to the right of the fuse access panel. This outlet will accept a standard automotive 12-volt accessory outlet and is intended for moderately powered accessories, such as a cellular phone. It will not operate large current items, such as cigarette lighters. WARNING! Damage to electrical components may occur from improper use. GEM Owner s Manual - Page 71

72 Understanding the Optional Features of Your Vehicle Accessory outlet cont WARNING! Do not plug in devices requiring power exceeding 25 watts. Damage to the vehicle electrical system may occur or an accessory fuse may blow. The fuse for the power outlet plug is located in the fuse block under the access panel in the center of the lower dashboard. Always use fuses with the same type and rating. Power outlets are designed for accessory plugs only. Do not hang any type of accessory or accessory bracket from the plug. GEM Owner s Manual - Page 72

73 Operation and Maintenance CONTENTS Basic Operation...74 What to do in Emergencies...74 Basic Maintenance...76 Care and Cleaning Vehicle Maintenance Schedule GEM Owner s Manual - Page 73

74 Operation and Maintenance BASIC OPERATION Basic procedure of how to operate the vehicle. 1. Turn on Main Disconnect Switch. 2. Fasten safety belts and adjust mirrors as necessary. 3. Turn key On. 4. Depress brake pedal and move direction switch to desired position. 5. Release parking brake. 6. Release brake pedal. 7. Press accelerator pedal and go. WHAT TO DO IN EMERGENCIES Error Code Summary and Explanation Error codes are used in the control system to indicate conditions that prevent the vehicle from operating. All error codes are accompanied by the service icon. The chart shown below summarizes the most frequent error codes and remedies. Error Code Condition Remedy 06 Pedal depressed and no direction is selected. Release pedal and insure direction switch is locked into a position. 11 Pedal is depressed when key is turned on. Release accelerator pedal and restart car. 15 Low voltage on battery pack. Need to charge batteries before operating. 16 High voltage on battery pack. Turn lights on for several seconds, then turn key switch off, and back on again. GEM Owner s Manual - Page 74

75 Operation and Maintenance Note: If any other codes are present, contact your GEM dealer or customer service for assistance. Transporting Your Vehicle The best way to transport your vehicle is in an enclosed trailer. If it is necessary to transport your vehicle on an open trailer, follow these guidelines: 1. Never transport your vehicle while the vehicle is facing rearward on the trailer. 2. With the vehicle facing forward, pull the trailer at speeds of 65 MPH or less. 4. If your vehicle is equipped with hard doors, put all windows down. 5. Secure any items that could be affected by airflow through the vehicle. 6. Do not secure across any plastic body or floor panel component of the vehicle. Use tie down points on the frame identified with an X as shown on page 64. Note: GEM is not responsible for damage incurred or lost items due to vehicle towing. CAUTION! TOWING THE VEHICLE IS NOT RECOMMENDED. This vehicle is not designed for dolly towing. Any vehicle failures resulting from dolly towing will void warranty. GEM Owner s Manual - Page 75

76 Operation and Maintenance BASIC MAINTENANCE The main disconnect switch should be turned off before any vehicle maintenance is started. Battery Charging - The Main Disconnect Switch must be On before charging the batteries. Note: The type of batteries used in the vehicle will perform better when kept fully charged. Therefore, whenever possible, recharge the batteries. The GEM vehicle has a battery control and recharge system specially designed for electric vehicle usage. Depending on the model and options of your GEM vehicle, it may be equipped with floodedwet cell or valve regulated gel type lead acid batteries. There are also two possible battery placement configurations. The standard configuration consists of 6, 12-volt batteries with 2 of the batteries located under the battery access cover on the bed of the es, el, el XD, and e6 models (see page 84), or under the maintenance plate on the rear spat of the e2, e4, and e6 models, with the other 4 batteries located under the bench seat on all models. The optional configuration, available on the e6 and the el XD models, consists of nine, 8-volt batteries. On the el XD model, 6 of these batteries are GEM Owner s Manual - Page 76 WARNING!

77 Operation and Maintenance located under the bench seat, with the remaining 3 located under the access panel located on the bed. On the e6 model, 3 of the batteries are located under the middle seat pedestal, with access through the panel located on the front of that panel. 3 more batteries are located under the rear bench seat, with the final 3 batteries located under the access panel on either the rear bed or rear spat. The charging system is designed to maximize the battery pack life while recharging the pack in the shortest time with available household current (ground fault protected 110-volt, 15-amp, A/C outlet). The following guidelines will insure that you receive the maximum battery life and performance out of your GEM vehicle. Because of the high power draw at low states of battery charge, the AC outlet should be dedicated only to recharging you GEM vehicle. GEM Owner s Manual - Page 77

78 Operation and Maintenance New batteries will not perform to their fullest capacity until they have been discharged and recharged 20 to 30 times. Batteries should be fully charged before the first use. When recharging, it is preferable to have the battery pack at room temperature. Do not charge in direct sunlight, on hot pavement or at temperatures of 110 F or higher. Batteries should be charged after each use, if possible. In the first few years of life, your batteries should provide a range of up to 30 miles at 72 F. At 32 F, your range may be reduced to miles. This is a normal characteristic of electric vehicles. Your actual range my be affected by road conditions, terrain, weather, and driving habits. WARNING! Always wear safety glasses or approved eye protection when servicing the vehicle. Wear a full-face shield and gloves when working with or around batteries and electrical connectors. Always use insulated tools when working with or near batteries. GEM Owner s Manual - Page 78

79 Operation and Maintenance WARNING! Battery fluid is a corrosive acid solution and can burn or blind you. Do not allow battery fluid to contact eyes, skin or clothing. If acid splashes in eyes or on the skin, flush the area immediately with large quantities of water. Battery gas is flammable and explosive. Keep flame or sparks away from the battery or any other booster source. Do not allow battery cable clamps to touch each other. Battery posts, terminals and related accessories contain lead and lead compounds. Wash your hands after handling. CAUTION! It is essential, when replacing the cables on the batteries that the positive cable is attached to the positive post (+) and the negative cable is attached to the negative post (-). Battery posts are identified on the battery case as positive (+) and negative (-). Cable clamps should be tight on the terminal posts and free of corrosion. CAUTION! If the batteries are replaced, make sure they are the exact type and make originally supplied with the vehicle. Failure to follow this caution can result in damage to the vehicle s electrical system. GEM Owner s Manual - Page 79

80 Operation and Maintenance Battery Charger The battery pack should be charged whenever convenient and no matter the state of charge. If no green bars are lit, the battery pack should be put on charge as soon as possible. A full recharge cycle (state of charge showing only 1 red bar) can take 8 hours or more. Most recharge cycles will be shorter. CAUTION! Batteries can be permanently damaged (and the warranty voided) if allowed to remain 30 days or more with low charge. CAUTION! Fully charge batteries before storing. In hot climates, battery self-discharge will increase. In cold climates, batteries could freeze if not properly charged. If the vehicle will not be used for 10 or more days, unplug the car, turn the main disconnect switch OFF and arrange for monthly charging, OR leave the car plugged in and the main disconnect switch ON, (only up to 24 weeks). GEM Owner s Manual - Page 80

81 Operation and Maintenance Battery Charge Receptacle 1 1. Charging Receptacle Figure 18 - Charging Receptacle The Battery Charge Receptacle (Figure 18), is located on the hood. It accepts a standard, 3 wire, grounded, extension cord and should not exceed the following: 12 gauge wire with three wire grounded; 50 feet or less in length. 14 gauge wire with three wire grounded; 25 feet or less in length. NOTE: Never use less than 14 gauge cord or cord longer than 50 feet to charge your GEM. WARNING! Use the correct gauge extension cord as defined above. An incorrect gauge extension cord could result in a fire, heat damage or charger failure. Insert the proper grounded extension cord into the battery charger receptacle (Figure 18), and then plug into a 110-volt A/C, 15 amp breaker outlet. A GFI (Ground Fault Interrupt) receptacle is recommended. An optional GEM GFI cord set is available from your GEM Dealer or Customer Service if you do not have a GFI receptacle at your regular recharge site. CAUTION: Periodically check extension cords for cut, abrasive or loose connections. Never leave extension cords in standing water. Do not drive over extension cords. GEM Owner s Manual - Page 81

82 Operation and Maintenance Battery Care Your GEM vehicle is equipped with six 12-volt Gel or flooded batteries. Both types are shown in Figure Figure 19 - Gel and flooded batteries 1. Gel 8-volt Battery 2. Flooded 12-volt Battery 3. Gel 12-volt Battery CAUTION! Each vehicle is programmed at the factory for a particular battery type. Switching battery types can only be done by a GEM certified technician. GEM Owner s Manual - Page 82

83 Operation and Maintenance Flooded Battery Fill Well Top of Battery Battery Plates 1 2 Figure 20 - Fill Wells of flooded battery 1. Bottom of Fill Well 2. Vented Cap The detailed view in Figure 20 shows the internal features of a fill well. Each battery contains two vented caps and six fill wells. Figure 20 shows one vented cap removed to show the three fill wells. *See Page 86 for filling instructions Note: Gel batteries do not have fill wells, as they are maintenance free. GEM Owner s Manual - Page 83

84 Operation and Maintenance Battery Location for es, el, and el XD Models Four of the batteries are located under the bench seat and two of the six batteries are located under the battery access cover in the center of the bed. The battery access cover, as shown in Figure 21, can be removed by unscrewing four fasteners. #8 X 3/4 Phillips Flat Head, Type-A Figure 21 - Short back bed battery access GEM Owner s Manual - Page 84

85 Operation and Maintenance Battery Location for e2, e4, and e6 Models On the e2 and e4 models four batteries are under the seat and two of the six batteries are located under the maintenance plate located in the center of the rear spat. It may be necessary to remove any rear accessory options before removing the cover. Figure 22 - Spat battery access To keep batteries in good working condition, follow the maintenance schedule listed below and discussed on pages Monthly Battery Maintenance 1. Check water level (flooded only) 2. Wash tops and terminals of batteries and allow to dry 3. Check terminal connections 4. Check battery hold down bar to insure batteries are tightly secured 5. Check for worn insulation or frayed wires Note: For more information or if a problem exists, contact GEM Service at GEM Owner s Manual - Page 85

86 Operation and Maintenance BATTERY MAINTENANCE WARNING! HIGH VOLTAGE The battery pack is at a high voltage. High voltage is always present at the battery terminals. Never touch the battery terminals when performing monthly battery maintenance procedures. 1. The water level in the flooded batteries should be checked monthly, or more frequently with heavy usage. The level should be in between the battery plates and the bottom of the fill well (see page 83). The battery plates should be visible when looking into the fill well. If not, use a flashlight. Add (distilled) water only after charging unless the water level is below the top of the battery plates. In this case, add just enough distilled water to cover the plates, charge then recheck the level. CAUTION! Never charge batteries if plates are exposed above water level. CAUTION! Battery acid from cleaning batteries can damage driveway or garage floor. Note: For best battery life, add only distilled water. GEM Owner s Manual - Page 86

87 Operation and Maintenance 2. Make sure the battery caps are firmly in place after maintenance and before washing. (See step 3) 3. Batteries should be kept clean and free of corrosion. Wash the tops and terminals of batteries with a solution of baking soda and water (1 cup baking soda per gallon of water) once per month. Review the CAUTIONS on pages Note: Do not allow the cleaning solution to enter the battery. WARNING! Improper handling of high voltage wiring, batteries, or control systems could result in serious or fatal injury by electric shock. Only qualified technicians should repair or access high voltage wiring, battery packs, and associated systems. GEM Owner s Manual - Page 87

88 Operation and Maintenance CAUTION! If battery cable terminals are damaged or corroded, they should be replaced or cleaned as necessary. Failure to do so may cause them to overheat during operation. 5. The battery hold down bars should be snug to keep batteries from moving while the vehicle is in motion, but not so tight as to crack or buckle the battery case. Make sure the lynch pin is in the proper position and locked. 6. Worn insulation, frayed cables, or damaged cable ends should be replaced immediately by a GEM certified technician. Note: After each use, the batteries should be charged. The batteries should never be left discharged. Battery Disposal Lead-acid batteries are recyclable. Return whole scrap batteries to distributor, manufacturer or lead smelter for recycling. For neutralized spills, place residue in acid-resistant containers with absorbent material, sand or earth and dispose of in accordance with local, state and federal regulations for acid and lead compounds. Contact local and/or state environmental officials regarding disposal information. You can also contact GEM Customer Service at for information. GEM Owner s Manual - Page 88

89 Operation and Maintenance Battery Care During Storage To allow for extended storage time, your GEM vehicle has several features to enhance battery life. A fully charged vehicle can be stored (with the ignition key in the OFF position), for up to 10 days. It will lose some of its charge during this period. When storing, or not using, your GEM for an extended period of time, (two weeks or longer) it is recommended that you first check the water level of your batteries, unless equipped with maintenance free gel batteries, and leave the vehicle plugged in with the Main Disconnect Switch in the ON position. The charger will monitor the state of charge of the batteries, and will initiate a charge cycle whenever the batteries fall to a pre-determined charge level, for up to 24 weeks. Note: In the case that the GEM vehicle can not be left plugged in for extended periods of time, the recommended method is to check the water level of flooded batteries, charge the car to 100% and then turn the MDS to the OFF position. When storing your vehicle in this condition for 30 days or more, it is necessary that arrangements are made to have the vehicle recharged every 30 days while in storage. To eliminate battery charge loss due to component current drain, or if the vehicle will be stored for more than 10 days, the car should be fully charged and the main disconnect switch must be turned OFF. The main disconnect switch can be seen on page 39. GEM Owner s Manual - Page 89

90 Operation and Maintenance WARNING! HIGH VOLTAGE The main disconnect switch will disable the vehicle by disconnecting the battery pack from the motor. It does not disable the battery pack. HIGH VOLTAGE will be present at the battery terminals. HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY TERMINALS GEM Owner s Manual - Page 90

91 Operation and Maintenance Brake Fluid Level 1. Reservoir 2. Cap 3. Maximum Level Mark 4. Minimum Level Mark The brake fluid reservoir (Figure 3 23) is located under the hood, above and to the rear of the 4 left front tire. The fluid level of your brake system is a very important safety component. It Figure 23 - Brake Fluid Reservoir should be checked according to the Vehicle Maintenance Schedule, on Page 104, by observing the side of the reservoir and noting its level. The fluid level should be at the maximum level mark. If it approaches the minimum level mark, fill it with DOT3 brake fluid and see your dealer for service or call Customer Service immediately at CAUTION: Brake fluid may cause damage to painted and finished surfaces. Use caution when refilling the brake fluid reservoir. 1 2 GEM Owner s Manual - Page 91

92 Operation and Maintenance Note: The vehicle is equipped with a four-wheel hydraulic braking system. Use standard DOT3 brake fluid. Tires Proper tire inflation pressure is essential to the safe and satisfactory operation of your vehicle. Tire inflation pressures are provided on your vehicle s VIN/Certification Label (See page 9, Figure 1). Three primary areas are affected by improper tire pressure. 1. Safety Under-inflation increases tire flexing and can result in tire failure. Over-inflation causes a tire to lose its ability to cushion shock. Objects on the road and potholes could cause tire damage that may result in tire failure. Unequal tire pressure can cause steering problems. GEM Owner s Manual - Page 92 CAUTION! CAUTION! After inspecting or adjusting the tire pressure always reinstall the valve stem cap-if equipped. This will prevent moisture and dirt from entering the valve stem, which could damage the valve stem.

93 Operation and Maintenance 2. Range Improper inflation pressures can cause uneven wear patterns to develop across the tire tread. These abnormal wear patterns will reduce tread life resulting in premature replacement. Under-inflation increases tire rolling-resistance, resulting in lower vehicle range. 3. Ride Comfort and Vehicle Stability Proper tire inflation contributes to a comfortable ride. Over-inflation produces a jarring and uncomfortable ride. Both under-inflation and over-inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness. Replace valve stem caps after tire maintenance to prevent dirt from damaging valve stem or preventing the stem from closing properly. 4. Wear Any accelerated wear of tires may be an indicator of improper alignment or poor driving habits. If uncertain, consult your GEM service provider. WARNING! Improperly inflated tires are dangerous and can cause accidents. Under inflation increases tire flexing and can result in tire failure. Over inflation reduces a tire s ability to cushion shock. Objects on the road and chuck holes can cause damage that results in tire failure. Unequal tire pressures can cause steering problems. You could lose control of your vehicle. GEM Owner s Manual - Page 93

94 Operation and Maintenance WARNING! Overinflated or under inflated tires can affect vehicle handling and can fail suddenly, resulting in loss of vehicle control. Unequal tire pressures from one side of the vehicle to the other can cause the vehicle to drift to the right or left. Always drive with each tire properly inflated. Replacement Tires The tires on your new vehicle provide a balance of many characteristics. They should be inspected regularly for wear and correct inflation pressure. GEM strongly recommends that you use tires equivalent to the originals in quality and performance when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety, handling, and ride of your vehicle. We recommend that you contact your dealer or GEM Customer Service regarding any questions you may have on tire specifications or capability. GEM Owner s Manual - Page 94

95 Operation and Maintenance WARNING! Do not use a tire size other than that specified on your vehicle s tire label. Improperly sized tires can cause vehicle components to wear out prematurely and may change your vehicle s ride, handling, and steering behavior. In addition, it may affect the accuracy of your speedometer/odometer. Using tires sized other than specified on your vehicle s tire label could cause you to lose control resulting in serious injury or death. Never use a tire smaller than the minimum tire size listed on your vehicle s tire label. Using a smaller tire could result in tire overload and failure. Failure to equip your vehicle with tires having adequate speed capability can result in sudden tire failure and loss of vehicle control. Overloading your tires is dangerous. Like under inflation, overloading can cause tire failure. Use tires of the recommended load capacity for your vehicle and never overload them. NOTE: The vehicle s tire information can be found on the VIN/Certification label (See page 9, Figure 1). GEM Owner s Manual - Page 95

96 Operation and Maintenance WARNING! Do not use a tire, wheel size or rating other than that specified for your vehicle. Some combinations of unapproved tires and wheels may change suspension dimensions and performance characteristics, resulting in changes to steering, handling, and braking of your vehicle. This can cause unpredictable handling and stress to steering and suspension components. You could lose control and have an accident resulting in serious injury or death. Use only the tire and wheel sizes with load ratings approved for your vehicle. GEM Owner s Manual - Page 96

97 Operation and Maintenance Tire Changing and Jacking And Tie-Down Points Figure 24 - Jacking and Tie Down Points (X) Tie-down points for transporting your GEM, see page 75 for transporting vehicle. In the event of a flat tire, GEM recommends using the GEM dealer network or GEM Customer Service to change it, because they have the proper equipment. Should you choose to change the tire yourself, you need to observe the following precautions: Park the vehicle on a firm level surface; avoiding icy or slippery areas. GEM Owner s Manual - Page 97

98 Operation and Maintenance Set the parking brake and block both the front and rear of the tire diagonally opposite the jacking position. For example, if the right front tire is being changed, block the left rear wheel. Use a small floor style jack or low profile scissors jack only. Jack the vehicle only from the side of the vehicle, on the main frame rail, at the point where the tub or floor panel support and the main frame rail are welded (See page 97, Figure 24). Alternative locations include the rear frame rail and the center of the front cross member. Tire Lug Nut Torque Specification: 65 ft-lbs, or 88 N-m WARNING! Getting under a jacked-up vehicle is dangerous. The vehicle could slip off the jack and fall on you. Never get any part of your body under a vehicle that is on a jack. Never start or run the motor when the vehicle is on a jack. If you need to get under the vehicle, make sure the vehicle is first located on a flat solid surface, and is supported securely by automotive jack stands or, take the vehicle to a service center where a technician can put it on a properly adjusted hoist. Jacking at any location other than the proper jacking points may cause major vehicle body damage. GEM Owner s Manual - Page 98 CAUTION!

99 Operation and Maintenance Fuse Access Panel/Fuse Block The fuse block (Figure 25) is located inside the fuse access panel (Figure 26), which is on the lower dash. The ignition key opens the fuse access panel. To open, turn the key counterclockwise one quarter turn. Figure 26 - Fuse Access Panel Figure 25 - Fuse Block GEM Owner s Manual - Page 99